LENS, IN PARTICULAR OPHTHALMIC LENS, AS WELL AS METHOD AND DEVICE FOR THEIR MANUFACTURING AND PITCHING PACKAGE WITH THE LENS

Description

[0001] The present invention relates to a method and a device for manufacturing a lens, in particular an ophthalmic lens, by filling a casting pack, in particular a casting pack with a small gap dimension and / or with a casting resin for forming a photochromic coating, as well as the casting pack and a lens, preferably ophthalmic and / or having at least a photochromic coating.

[0002] Lenses, especially ophthalmic lenses, particularly spectacle lenses, can be manufactured in various ways. One well-known manufacturing method is a casting process, which uses a front and a back mold, also known as a casting mold. Such a mold is a negative mold or negative mask of the final lens shape; that is, for a convex or concave surface of a lens to be cast, a mold is needed that has the opposite shape, i.e., a concave or convex form. Of course, a multitude of other shapes are also conceivable and are used to produce customized lenses.In this casting process, a front and a rear mold shell are positioned at a defined distance from each other. A casting resin, which after hardening will form the final lens, is then poured into the resulting cavity defined by the front and rear mold shells. Depending on the composition of the resin, hardening then occurs either thermally, i.e., by tempering at a temperature that promotes the hardening of the resin, or photochemically, i.e., by inducing a chemical reaction through irradiation with electromagnetic radiation of a suitable wavelength. This includes, in particular, a process in which the casting resin hardens through irradiation with UV radiation.The casting resins used are not severely restricted and only need to meet the requirement of sufficient optical quality with regard to the optical imaging properties of the final lens. Additionally, the casting resins can contain further components that impart desired, preferred properties to the final lens, such as a tailored refractive index or desired absorption properties, particularly protection against harmful UV radiation. After curing, the front and rear mold shells are removed, yielding the lens. Further processing or finishing steps can then follow, such as incorporating a defined optical effect.In the case of an ophthalmic lens, this refers to an optometric prescription for the correction of a determined refractive error by means of suitable processing methods, in particular milling and grinding processes, as well as the application of various coatings to obtain a shatterproof, scratch-resistant, possibly photochromic, anti-reflective or reflective, and / or dirt-repellent lens. Especially if the lens thus obtained undergoes further processing steps, such a lens constitutes an intermediate product from the perspective of the overall manufacturing process, which is why the present item is also referred to as a semi-finished product, lens semi-finished product, or, analogously, spectacle lens semi-finished product.

[0003] Photochromic lenses react to UV radiation. Depending on the intensity of the UV radiation hitting the lens, it darkens or lightens. This darkening or lightening of the lens is made possible by a functional tint. This tint is produced by a photochromic dye that undergoes a reversible change in its molecular structure, also known as isomerization, thereby altering its absorption properties in response to UV radiation. When the UV radiation subsides, the photochromic dye reverts to its original molecular structure and thus its original absorption properties. A photochromic dye therefore allows for a reversible switching between dark and light tints. Such a functional tint can be achieved in various ways.One method, also known as mass coloring, involves the casting process mentioned earlier, with the dye being directly added to the casting resin. Functional coloring can also be applied to a lens by coating it with a thin layer or by applying a layer containing a photochromic dye.

[0004] From the prior art, a multitude of possibilities are known to those skilled in the art for applying or forming additional thin layers, such as photochromic coatings, onto a lens, including in particular spin coating and dip coating.

[0005] In the case of dip coating, the lens to be coated is immersed in a bath containing at least one photochromic dye, resulting in a photochromic coating on both sides of the lens. Such dip coating is not very complex in terms of equipment and can be carried out in conventional dip coating systems. However, it has the disadvantage that achieving the cosmetic finish necessary for ophthalmic lenses is difficult and / or that the double-sided coating results in high material consumption, which, especially with complex photochromic dyes, represents an economic disadvantage due to the increased manufacturing costs.

[0006] Although spin coating applies the desired photochromic coating to only one of the two sides of the lens, thus reducing material requirements, this method has the disadvantage that spin coating is produced in batch sizes of one piece, which is time-consuming in handling and leaves little room for cost-saving automation measures.

[0007] In particular, the production of a photochromic lens, especially a photochromic ophthalmic lens, cannot be achieved using the casting process mentioned earlier, with the addition of photochromic dyes to a casting resin, or at least not without disadvantages. One reason for this is that casting resins for ophthalmic lenses usually contain UV absorbers to protect the resulting ophthalmic lens from harmful UV radiation. UV absorbers are inherently in competition with photochromic dyes, as both react to incident UV radiation. Another reason is the cross-linking of the casting resin during curing, which negatively affects the isomerization behavior of the photochromic dyes or restricts it to such an extent that a photochromic reaction can only occur with significant impairment or not at all. In addition to these technical reasons, economic factors also play a role.The volume of material between the two mold shells in such a casting process, which will later form the lens, typically has a medium thickness of several millimeters to provide the finished lens with a minimum level of impact resistance. Adding complex, highly specific photochromic dyes to a casting resin would require a large quantity of these dyes, significantly increasing the manufacturing costs of such a photochromic spectacle lens. Even greater is the amount of dye that is removed and discarded during the surface finishing of the aforementioned semi-finished part.

[0008] Accordingly, for the manufacture of lenses with at least one, in particular non-linear, optical functionality, it can be advantageous to separate this functionality as a coating or overlay from a lens substrate, for example, a lens or spectacle lens semi-finished component as described above. This applies in particular to equipping an ophthalmic and / or plastic lens, especially a spectacle lens, with at least one photochromic coating or layer, which preferably comprises at least one photochromic organic dye. Therefore, the present invention is explained below in part with reference to this particularly preferred application of a lens, in particular a spectacle lens, with at least one, preferably thin, photochromic coating, without, however, being limited to this application.

[0009] An injection molding device known from US 2022 / 219361 A1 comprises a substantially circular first substrate, a substantially circular second substrate arranged to face a surface of the first substrate, a fastening element securing a peripheral end section of the first substrate and a peripheral end section of the second substrate, and an injection section provided in the fastening element from which a composition is injected into a gap between the first substrate and the second substrate, wherein a space connecting the injection section and the gap is provided in at least a part of a circumference of the gap and a width of the space in a thickness direction is greater than a width of the gap in the thickness direction.

[0010] The task is to provide an improved method for manufacturing a lens, in particular a method that addresses the previously discussed disadvantages with regard to the manufacture of a lens with a thin layer, which is particularly preferably understood to be a photochromic coating.

[0011] This problem is solved by a method according to claim 1.

[0012] An objective may also consist of providing a device for carrying out a method described herein or providing an advantageous lens, preferably ophthalmic and / or manufactured according to a method described herein.

[0013] This problem is solved by a device according to claim 13, which is configured or used to carry out a method described herein, or by a lens produced according to a method described herein. Accordingly, the present explanations and / or features apply equally to a method, a device according to the invention, and a lens produced according to a method according to the invention, even if they are mentioned only with reference to one of these aspects. In particular, the use of a casting package described herein in a method described herein, or the use of a device described herein for carrying out a method described herein, is also protected. The dependent claims relate to advantageous embodiments.

[0014] One aspect of the invention relates to a method for manufacturing a lens, in particular a spectacle lens, comprising at least one of the following steps: S100: Providing a basic body, S102: Provide a mold tray, S104: Arranging the base or glass body and the mold shell in such a way that a cavity is formed between the base or glass body and the mold shell. S106: Applying a sealing strip creates a seal between the base or glass body and the mold shell to maintain a casting package, S108: Forming at least one opening in the sealing tape, S110: Arranging the casting package in a holding device, S112: Filling the cavity through at least one opening with a casting resin, S114: Closing the opening, S116: Removing the casting package filled with casting resin from the holding device, S118: Curing of the casting package, S120: Removing the sealing tape, and S122: Removing the mold shell to obtain a lens.

[0015] The method according to the invention enables the production of a lens by means of a casting process. Preferably, it comprises at least steps S100, S102, wherein the mold shell can be provided before, after, or with the base body, steps S104, S106, S112, S120, and S122, preferably in this order, wherein, in an advantageous embodiment, one or more of steps S108, S110, S116, S114, and S118 are provided, preferably in the order indicated by the (ascending) numbering of the respective step with reference to each other, and / or the aforementioned steps S100, S102, S104, S106, S112, S120, and S122, without the invention being limited thereto.

[0016] Advantageously, the surface of the coating, applied in one embodiment by the curing of the casting resin, can be shaped, and in a preferred case, i.e., in the case of a coating that is as homogeneous as possible (meaning a uniform coating and a coating with a layer thickness that is almost independent of location), the surface of the coating is almost identical to the surface of the uncoated lens. Preferably, a modification of the surface, which can be understood in particular as structuring with, for example, targeted raised areas, can be achieved by means of this method.

[0017] Advantageously, this method can be used to produce a coating, a sprue, or an overlay on a substrate that has a small gap dimension, preferably less than 1,000 µm, particularly preferably a few hundred micrometers, and preferably less than 500 µm. In one embodiment, the gap dimension of the cavity, whether maximum or averaged over the entire surface, is less than 1,000 micrometers (1,000 µm), and particularly preferably less than 500 µm. In one embodiment, the casting resin forms a photochromic coating and may (for this purpose) particularly comprise at least one photochromic, and more preferably, an organic dye. The present invention is particularly advantageous for such thin and / or photochromic coatings, especially due to the requirements in manufacturing and / or with regard to quality and / or materials, but is not limited to these applications.The coating formed by the casting resin can have or implement at least one other optical functionality besides the photochromic one. In a preferred embodiment, the mold shell or casting form is arranged on an object-side, environment-side, or non-eye-side front face of the base body, so that the coating formed by the casting resin is accordingly formed or arranged on an object-side, environment-side, or non-eye-side front face of the lens, which can be particularly advantageous functionally.

[0018] In process step S100, a base body is provided, which can be any substrate or support material onto which a casting resin is poured using this process. After appropriate curing, this results in a sprue, layer, overlay, additional component, or additional layer on the base body. To be suitable for its subsequent use as a lens, the base body should possess sufficient optical quality with regard to optical imaging properties. Those skilled in the art understand optical imaging properties to be a multitude of determinable, characteristic quantities that can characterize a given object, such as a base body in particular, with respect to its optical imaging properties. These include properties such as spectral transmission, color rendering, and the Abbe number.Particularly in the use of plastics as materials for the manufacture of lenses, especially ophthalmic lenses or spectacle lenses, materials such as poly(thio)urethane, polyacrylate, polymethyl methacrylate, polycarbonate, polydiethylene glycol bisallyl carbonate, or combinations thereof have proven preferred in recent years, although other transparent plastic materials can also be used in principle. Accordingly, the base body in one embodiment comprises plastic, and can in particular be a plastic base body, preferably a plastic lens base. In a preferred embodiment, the base body is manufactured using a casting process mentioned above and has at least a first optical effect and can therefore also be described as a semi-finished part, since at least the first or the second side or surface, or both sides or surfaces, are already present.The surfaces of the base body already possess a desired geometric shape, which in particular includes a defined radius of curvature. Such a base body can also be a fully processed lens, which is provided with an additional layer or overlay as part of the process.

[0019] In one embodiment, the base body (onto which the subsequent sprue is made) comprises a plastic material, preferably of corresponding optical quality, which is composed of polymerizable molecules, preferably of optical quality. In a further development, the base body consists of such a plastic material. These polymerizable compounds can be, in particular, monomers, oligomers, and / or prepolymers. Preferably, one, several, or combinations of the following are used to provide or as thermally curable polyurethane and polythiourethane casting resins, especially for the production of the base body: multifunctional isocyanates, isothiocyanates, and / or episulfides, multifunctional alcohols, and / or thiols. Also preferably, one, several, or combinations of the following are used to provide or as thermally curable polyurethane and polythiourethane casting resins, particularly for the production of the base body.The following are used as thermally and / or photochemically curable polyacrylate and polymethyl methacrylate casting resins, particularly for the production of the base body: multi- and / or monofunctional acrylates and / or methyl methacrylates. Also preferred are one, several, or combinations of the following for the provision of, or as thermally curable polycarbonate and polydiethylene glycol bis(allyl carbonate) casting resins, particularly for the production of the base body: multi- and / or monofunctional allyl carbonates and / or diethylene glycol bis(allyl carbonate).

[0020] Such compounds or plastic materials are offered under trademarked trade names such as CR-39, CR-607, CR-630, or MR-7, MR-8, and MR-10. CR-39, or Columbia Resin 39, is distributed by Pittsburgh Plate Glass Industries (PPG Industries) and is a thermosetting polymer. CR-607 and CR-630 also come from PPG Industries. The trade names MR-7, MR-8, and MR-10 refer to polythiourethanes distributed by Mitsui Chemicals. The abbreviation "MR" stands for Mitsui Resin.

[0021] In addition to or as an alternative to these preferred materials, other transparent plastic materials may also be used, without restriction.

[0022] In a further process step S102, which, as already mentioned, can be carried out before, with, or after process step S100, a mold is provided. This mold is defined as an object that has at least one surface which corresponds to the opposite shape of the desired lens surface to be obtained after carrying out the process. This surface of the mold represents the negative image of the lens surface to be obtained. In the simplest case, the mold therefore has a curved surface, which is concave or convex depending on the desired surface of the lens to be obtained, if the lens surface is to be correspondingly convex or concave. Of course, combinations of these are also conceivable, as are, in particular, any shape.Advantageously, the mold shell can also contain structures, and it would therefore be conceivable to provide the mold shell with recesses that, after casting, leave corresponding protrusions on the lens, which can lead to the formation of microlenses. Preferably, a multitude of microlenses can be formed on the subsequent lens by using such a modified mold shell, which can be particularly advantageous when using such a lens as an ophthalmic lens in a spectacle lens, especially for the treatment of myopia.

[0023] In a further process step S104, the previously provided base body and the provided mold shell are arranged. This preferably means that the base body and mold shell are arranged or positioned relative to each other such that they are at a defined distance from one another, thereby forming a cavity between them. Preferably, the base body and mold shell are arranged relative to each other such that a cavity with a small gap is formed between them, preferably a gap, in particular a maximum or averaged gap of less than or equal to 1,000 µm, preferably less than or equal to 500 µm.

[0024] A further process step S106 comprises the application of a sealing tape, also called tape, such that a seal, preferably gas- and / or liquid-impermeable, or in one embodiment an airtight and / or liquid-impermeable seal with respect to the liquid casting resin, is created in the cavity formed between the base body and the mold shell. The choice of a suitable sealing tape is not severely restricted. In principle, any suitable adhesive tape is conceivable as long as it ensures the required seal, adheres to the base body and the mold shell, and can also be detached and removed again in a later process step. Preferably, the sealing tape has high chemical resistance to the casting resin used and is advantageously pressure-resistant, since in one embodiment the process is intended to allow the subsequent filling of the cavity, particularly with casting resins of high viscosity.Furthermore, the filling time can be shortened if filling takes place under higher pressures. The sealing tape can be applied either manually or by a suitable device that holds the sealing tape in a reservoir, preferably on a roll, and then, by a rolling or unwinding process, rolls or wraps at least one layer of the sealing tape around the assembly consisting of the mold shell and base body, with the aim of achieving the required (gas- and liquid-tight) seal. In one embodiment, the sealing tape has a carrier material, preferably PET, OPP, or the like, and / or an adhesive, preferably an acrylic adhesive, silicone adhesive, or the like. These are particularly suitable due to the requirements of filling with casting resin, preferably under overpressure.

[0025] An object obtained in this way, consisting of a base body, a mold shell arranged at a defined distance from it, forming a cavity, and enclosed with a sealing strip, is also called a casting package.

[0026] A further process step S108 can include forming at least one initial opening in the sealing tape in order to be able to pour a casting resin into the cavity at a later time via said opening ("inlet opening" or "filling opening"). Such an initial opening can be formed and optionally carried out by a device which is suitable for a mechanical process for forming a initial opening, such as cutting, piercing or punching, or a thermal process for forming a initial opening, such as targeted thermal heating or decomposition with a hot object or similar device.to carry out the process by means of an object having a hot surface which is brought into contact with the sealing tape at the desired location to form a first opening, or by means of a focused laser pulse which causes targeted thermal decomposition at the desired location to form a first opening.

[0027] In addition to a first opening as an inlet, at least one further, second opening can also be formed, which serves to allow the air displaced during the subsequent filling of the cavity to escape ("outlet"). Preferably, such a second opening is located opposite the first opening. Alternatively, the formation of a second opening as an outlet can be omitted if the cavity is evacuated before filling. Preferably, such evacuation takes place after the formation of a first opening; particularly preferably, the device used to form the opening and / or to fill with casting resin has, optionally in addition to its mechanical or thermal component for forming the opening, a corresponding evacuation capability.Additionally, multiple openings can be formed to allow filling from multiple positions simultaneously, for example. Alternatively, the sealing tape used can already be provided with one or more openings, so that step S108 in the inventive method is omitted, not part of the inventive method, or can be carried out before the sealing tape is applied, preferably by a third party such as a supplier of the sealing tape or the like. In one embodiment, the sealing tape has one or more openings, in particular one or more inlet openings and / or one or more outlet openings, which are formed before the sealing tape is applied, in an embodiment in which the method includes step S108. The formation of an opening orSeveral such openings are created at a defined location, preferably such that each opening has a defined size and neither the base body nor the mold shell is damaged during its creation. The opening(s) to be formed are defined with respect to their size or diameter. The diameter is selected such that, on the one hand, a desired volume flow rate can be achieved when filling with casting resin, and on the other hand, the size of the opening is not larger than the dimensions of the cavity behind it.

[0028] In one embodiment, the sealing tape is applied in a single layer, which reduces the process time, with an overlap of up to 90° or 25% of the casting package circumference still being considered a single layer. In another embodiment, the sealing tape is applied in multiple layers, or in such a way that at least one layer of the sealing tape overlaps at least one other layer of the sealing tape over more than 90° or more than 25% of the casting package circumference, preferably at least 180° or at least 50% of the casting package circumference, and particularly preferably over 360° or 100% of the casting package circumference. This can improve the stability and / or sealing.

[0029] In one embodiment, preferably in a further development before, and in a particularly preferred further development after, the sealing tape is applied to create a seal for the cavity formed between the base or glass body and the mold shell to retain the casting package. Two or more openings are formed in the sealing tape, wherein the cavity is filled with the casting resin through a first of these openings, and wherein the cavity is also filled with the casting resin through one or more second of these openings, i.e., the cavity is filled with the casting resin through at least two (inlet) openings, and / or gas, in particular air, escapes from the cavity through at least one second of these openings during filling, which accordingly forms an outlet opening. This improves the filling process, in particular making it faster and / or more uniform and / or reducing the probability of bubble formation.

[0030] In one embodiment, the formation of the at least one opening(s) in the sealing strip takes place after the sealing strip has been applied, whereby the (respective) opening can advantageously be formed particularly precisely and / or easily at the (respective) desired location of the casting package. In another embodiment, the formation of the at least one opening(s) in the sealing strip is carried out by means of a mechanical opening device, or mechanically, in particular by cutting, piercing, punching, or the like, whereby the (respective) opening can advantageously be formed particularly quickly, precisely, and / or easily, especially at a predetermined location of the casting package. In another embodiment, the formation of the at least one opening(s) in the sealing strip is carried out by means of a thermal opening device, or thermally, in a further development by thermal heating.Decomposition with a hot object or with an object having a hot surface, which is brought into contact with the sealing strip at the desired location to form the (respective) opening, whereby the (respective) opening can advantageously be formed with minimal deformation, particularly at a predetermined location of the casting. In one embodiment, the formation of the at least one or at least one of the opening(s) in the sealing strip is carried out using laser light, whereby the (respective) opening can advantageously be formed particularly quickly and / or precisely, particularly at a predetermined location of the casting.

[0031] A further process step S110 can include arranging the casting package in a holding device, wherein the casting package is then preferably removed from the holding device in a further process step S116 after filling the cavity with the casting resin, preferably after closing the opening(s) and after or particularly preferably before the casting package has hardened.

[0032] A further process step, S112, involves filling the cavity of the casting package with a casting resin. A casting resin can be understood to be, in particular, any composition which, in its liquid or uncured state, has a viscosity of up to 800 mPas and / or which, after curing, is suitable to form a body suitable for use as a lens or lens coating. This specifically means that such a casting resin consists of a composition which, even before, and especially after, curing, possesses optical quality with regard to its optical imaging properties that makes it suitable for use as a lens or lens coating. The process is particularly suitable for the use of higher-viscosity or high-viscosity casting resins.Preferably, transparent plastic materials such as poly(thio)urethane, polymethyl methacrylate, polycarbonate, polyacrylate, polydiethylene glycol bisallyl carbonate, or combinations thereof can be used as the casting resin. Additional components can also be added to such a casting resin, such as those that achieve a desired absorption behavior, particularly increased absorption in the UV range to provide UV protection in the finished lens. Furthermore, components can be added that modify the refractive index of the casting resin, especially to match the refractive index of the base body, thus preventing additional light refraction at the interface between the sprue and the base body. Dyes can also be added to achieve a desired color.Depending on the type and properties of the additional components, it may also be necessary to add dyes to mask any existing pre-coloration of the casting resin. For example, if additional components provide enhanced protection against the transmission of radiation from the ultraviolet and blue spectral ranges by increasing absorption in these ranges, the resulting targeted removal of radiation, particularly from the visible spectrum (at least partially removing blue light), can lead to a non-neutral color rendering of light transmitted through the lens. In such a case, this is referred to as an inherent coloration, which in the above example would give the lens or lens coating a yellow tint. This can, in turn, be corrected by adding a blue dye to achieve a neutral lens coloration.Preferably, the cavity is filled with a casting resin comprising polymers, preferably polyhydric acrylates and polyhydric methacrylates of high molecular weight, and also particularly preferably, the cavity is filled with a casting resin comprising polyadducts, in one embodiment (comprising a casting resin) polymers, preferably polyhydric acrylates and polyhydric methacrylates of high molecular weight as polyadducts, polyhydric isocyanates, polyhydric thiols and polyhydric alcohols in combination with photochromic dyes, preferably long-chain substituted as disclosed in WO 2019 / 238495, the disclosure of which is incorporated in this respect into the present disclosure. Advantageously, by adding photochromic dyes in particular to the casting resin, a casting resin for forming a sprue with photochromic properties can be obtained, which is why this sprue can also be referred to as a photochromic sprue.The casting resins of the polyadducts described above tend to form prepolymers, especially during extended periods of inactivity. Particularly with urethane casting resins containing the aforementioned dyes, viscosities are reached that prevent easy filling.

[0033] In one embodiment, the casting resin with which the cavity is filled through the at least one opening, or the sprue (on the base body), comprises a plastic material, preferably of high optical quality, which is composed of polymerizable molecules, preferably of optical quality, and can in particular consist of such a plastic material. These polymerizable compounds can in particular be monomers, oligomers, and prepolymers. Preferably, one, several, or combinations of the following are used to provide or as thermally curable polyurethane and polythiourethane casting resins: multifunctional isocyanates, isothiocyanates, and / or episulfides, multifunctional alcohols, and / or thiols. Also preferably, one, several, or combinations of the following are used to provide or as thermally curable polyurethane and polythiourethane casting resins.The following materials are used as thermally and / or photochemically curable polyacrylate and polymethyl methacrylate casting resins: multi- and / or monofunctional acrylates and / or methyl methacrylates. Also preferred are one, several, or combinations of the following for the provision of, or as thermally curable, polycarbonate and polydiethylene glycol bis(allyl carbonate) casting resins: multi- and / or monofunctional allyl carbonates and / or diethylene glycol bis(allyl carbonate). In addition to or as an alternative to these preferred materials, other transparent plastic materials may also be used, without limitation.

[0034] In one embodiment, a casting resin, preferably a low- or high-viscosity casting resin, is used for filling, which has a viscosity of up to 800 mPas during filling and / or in the uncured or liquid state.

[0035] In one embodiment, the casting resin (used for filling) comprises one or more, preferably photochromic and / or organic, dyes, particularly preferably one or more photochromic and organic dyes, and most preferably one or more naphthopyran dyes.

[0036] The filling of the cavity of the casting package with such a casting resin takes place by means of a suitable device, with which a casting resin can be filled through one or more of the previously formed (inlet) opening(s) in the sealing strip into the formed cavity behind that or the respective opening, or which cavity can be filled with a casting resin by means of such a device.

[0037] Preferably, such filling takes place by injecting, pouring, or dripping the casting resin through one or more of the filling openings into the cavity of the casting package located behind the filling opening. The cavity formed by the gap between the mold shell and the base body of the casting package is also referred to as the gap or, in particular, the gate gap. In one embodiment, the filling with, injecting, pouring, or dripping of casting resin through one or more of the filling openings is not carried out through a tube through which the respective filling opening has been formed and which, after this formation, remains at least partially in the respective filling opening for filling purposes; in particular, not by injecting through a tube used to form the corresponding filling opening and subsequently, after this formation, filling the corresponding opening.The filling opening formed by the sealing tape is formed by a needle passing through it. Particularly preferably, the filling with, injecting, pouring, or dripping of casting resin through one or more of the filling openings is carried out by at least one tube with at least one channel, and the formation of this or the respective filling opening(s) is carried out by a device separate from this tube, which may in particular also be a needle, or possibly a different one. Further preferably, the formation of the filling opening in the sealing tape, for example by a needle, can be carried out separately in time and / or space from the arrangement of a tube for filling with casting resin. For example, the sealing tape can be supplied as a roll with filling openings already formed, in particular at a predetermined distance.

[0038] The casting package can be in any orientation during filling. Preferably, a casting package is used which has exactly two formed openings, a first opening serving as an inlet opening and a second opening as an outlet opening. Such a preferred casting package is preferably oriented during filling such that the base body and the mold shell are horizontally adjacent, i.e., arranged side by side along a horizontal axis, and that the casting package is additionally oriented such that the outlet opening is above or higher with respect to a vertical axis of the casting package than the inlet opening. Preferably, filling takes place in a vertical orThe arrangement is vertical, meaning that the outlet opening is located on the upper side and forms the highest point of the casting package, and the inlet opening is located on the lower side of the casting package and forms the lowest point, i.e., the mass flow during filling with the casting resin occurs against the direction of gravity. Alternative arrangements are also conceivable and preferred, as long as the filling process is carried out in such a way that the mass flow during filling is at least substantially against the direction of gravity. In one embodiment, the cavity is filled under overpressure, in particular against ambient (air) pressure, and / or at least partially against the direction of gravity. Alternatively, the casting package can also be in a horizontal position during filling, meaning that the casting package is in a position in which the base body is above the mold shell or...in which the mold shell is located above the base body. In such a case, filling preferably takes place through several openings, particularly simultaneously. Advantageously, the casting package is arranged in a holding device to keep the first and second openings oriented according to a desired position. The casting package is preferably placed in the holding device before the casting resin is poured in and can be removed from the holding device after filling, particularly after curing. Filling under overpressure, filling at least partially against the direction of gravity, and especially filling under overpressure and at least partially against the direction of gravity can improve the filling process, in particular making it faster and / or more uniform and / or reducing the probability of bubble formation.

[0039] It is understood that a device can be provided which is suitable for forming one or more openings in a sealing strip of a casting package, for evacuating a cavity of a casting package, for filling a casting package with a casting resin, and for closing a formed opening in a casting package. Advantageously, this device can include means for piercing the sealing strip and for filling, for example, a sharp-edged hollow needle. However, hollow needles can be prone to pressure loss when closing a formed opening in a casting package, restricting the flow rate and promoting the escape of casting resin.Therefore, as already mentioned, it is particularly preferred to use one or more single- or multi-channel tubes, especially hollow needles, for filling the casting package with casting resin through one or more (filling) openings in a sealing strip of a casting package. These tubes connect to or extend through the respective opening(s), and a device different from the tube(s) is used to form these openings. This device can be arranged with the tube(s) on a common, particularly movable, support, preferably to enable the formation of the opening(s) and filling to be carried out quickly and / or with minimal adjustments. Alternatively, it can be actuated separately from the tube(s) to simplify the device and / or adjustment. A sealing element, preferably a surface-mounted one, is particularly preferred to provide a fluidic seal at the puncture point.

[0040] In a particularly preferred embodiment, filling the cavity comprises filling the cavity with the casting resin from a resin reservoir through a single- or multi-channel supply line, a molded part that is preferably sealing with respect to the casting resin and which, during filling, rests at least temporarily, preferably with a contact surface, on the casting package, and one or more of the (inlet) openings. In one embodiment, the molded part has at least one elastic layer for contacting or resting on the casting package(s) and can, in particular, consist of an elastic and correspondingly conformable material; moreover, the elastic layer or the elastic material can form the contact surface of the molded part.

[0041] In one embodiment, the molded part and the casting package are pressed against each other, in an advantageous further development with a defined and / or adjustable or set contact pressure and / or by means of a one- or multi-part pressing device, which in one embodiment has a, preferably mechanical, hydraulic or pneumatic, one- or multi-part spring and / or a, preferably adjustable, preferably motor-driven, hydraulic or pneumatic, in one embodiment robotically, adjustable, one- or multi-part mechanical guide, in particular can be.

[0042] An elasticity or flexibility to effect the, preferably defined and / or adjustable or set, contact pressure can be formed or provided in particular by an elasticity or flexibility of the casting package, especially the sealing strip, and / or, particularly advantageously, by an elasticity or flexibility of the molded part, especially the elastic layer(s) or the elastic material, and / or, also particularly advantageously, by the spring mechanism.

[0043] Accordingly, in one embodiment, the molded part and the casting package are pressed against each other by appropriate positioning of the molded part relative to the casting package, preferably by the mechanical guide, and / or of the casting package relative to the molded part, preferably by the mechanical guide, and / or by compression of the casting package and / or, particularly advantageously, the spring and / or of the molded part.

[0044] In one embodiment, the mechanical guide is adjusted manually or by at least one actuator, preferably electric, hydraulic, or pneumatic. In another embodiment, the mechanical guide has a fixing, preferably adjustable and / or friction-fit and / or positive-locking, for fixing the molded part relative to the casting pack and / or the casting pack relative to the molded part.

[0045] In one embodiment, the molded part is movable in a prestressing direction, and the casting package is rigidly supported in the prestressing direction. The molded part is pressed against the casting package in the prestressing direction by the pressing device, or, in a further development, by a spring (preferably mechanical, hydraulic, or pneumatic) and / or a mechanical guide (preferably motor-driven, hydraulic, or pneumatic, or, in one embodiment, robotically adjustable). This allows for a particularly advantageous mounting of the casting package.

[0046] In another embodiment, conversely, the casting package is movable in a prestressing direction, and the molded part is rigidly supported in the prestressing direction. The casting package is pressed against the molded part in the prestressing direction by the pressing device, or, in a further development, by a spring (preferably mechanical, hydraulic, or pneumatic) and / or a mechanical guide (preferably motor-driven, hydraulic, or pneumatic, or, in one embodiment, robotically adjustable). This allows for a particularly advantageous supply of casting resin.

[0047] In a further embodiment, the molded part is movable in a prestressing direction and the casting package is also movable in the prestressing direction, wherein the molded part is pressed against the casting package in the prestressing direction by the pressing device, in a further development a, preferably mechanical, hydraulic or pneumatic, (partial) spring and / or a, preferably motor-driven, hydraulic or pneumatic, in a further development robotically, adjustable, mechanical (partial) guide, and the casting package is pressed against the molded part in the prestressing direction by the pressing device, in a further development a, preferably mechanical, hydraulic or pneumatic, (partial) spring and / or a, preferably motor-driven, hydraulic or pneumatic, in a further development robotically, adjustable, mechanical (partial) guide.For example, the casting package can be flexibly supported by a (partial) spring, and the molded part can be pressed against the casting package by a mechanically adjustable guide (motorized, hydraulic, pneumatic, or, in one version, robotic) and / or a (partial) spring, or vice versa. This allows for particularly advantageous filling and / or sealing.

[0048] A (partial) suspension mentioned herein preferably comprises one or more mechanical, hydraulic, or pneumatic compression springs. A mechanical guide mentioned herein can be adjusted by a single- or multi-axis robot, in particular a robot arm, or the like, wherein a multi-axis robot (arm) is understood to be a one-, two-, three-, or more-axis manipulator for displacement in one, two, or three spatial directions and / or rotation about one, two, or three spatial directions. Accordingly, in one embodiment, a device for carrying out a method described herein, in a further development the pressing device, comprises such a single- or multi-axis manipulator or robot; in particular, the manipulator or the...A robot's mechanically, hydraulically, or pneumatically adjustable guide may first move the molded part towards the casting package and / or subsequently press it against the rigidly supported or flexibly mounted casting package with a defined and / or adjustable or set contact pressure. Similarly, the molded part can be manually positioned relative to the casting package, or the casting package can be manually positioned relative to the molded part and fixed in this position by the mechanical guide. By compressing the casting package and / or, particularly preferably, the correspondingly elastic molded part and / or an optionally provided spring mechanism, the molded part and the casting package are pressed against each other with a defined contact pressure.

[0049] One or more of the aforementioned features or designs, in particular the molded part and preferably the pressing device, can achieve a better seal compared to a channel inserted into the cavity, especially a cannula or the like inserted through the sealing tape or its (inlet) opening(s). The combination of the pressing described above with the formation of at least one opening in the sealing tape after its application by means of an opening device is particularly advantageous, as this allows for optimal sealing of these opening(s).

[0050] In one embodiment, the molded part or its contact surface has at least one opening, in particular an outlet opening, preferably a through-opening, which connects directly to at least one of the (inlet) openings in the sealing strip, at least during filling (in the direction of flow of the casting resin). The molded part can be designed as a single piece or in multiple parts, wherein the molded part or one or more of its parts can each have one or more such openings. An arrangement can be particularly advantageous in which each of the inlet openings in the sealing strip is directly connected to a separate opening of the molded part or its (optionally multi-part) contact surface. This allows for a particularly advantageous sealing and / or filling process. Likewise, at least one of the openings of the molded part can connect to two or more (inlet) openings in the sealing strip.These (inlet) openings are supplied or flowed through by the same opening of the molded part or its contact surface. This simplifies the design and / or positioning of the molded part.

[0051] In one embodiment, an edge of at least one of the opening(s) of the molded part or its contact surface completely surrounds, encloses, or encompasses an edge of the adjoining (inlet) opening(s) in the sealing tape. This allows for a particularly advantageous sealing and / or filling effect. In another embodiment, an edge of at least one of the (inlet) opening(s) in the sealing tape completely surrounds, encloses, or encompasses an edge of the adjoining opening(s) of the molded part or its contact surface. This simplifies the assembly and / or positioning of the molded part.

[0052] In one embodiment, the molded part and / or the opening device is adjusted relative to the casting package arranged in the holding device by means of a mechanical guide. This improves the filling or formation of the opening(s).

[0053] In one embodiment, the cavity is evacuated before filling; in a further development, this is done by means of the opening device or the molded part, which can first be connected to a suction pump and then switched to the casting resin reservoir.

[0054] In one embodiment, the resin reservoir can have a pressure device for filling the cavity under overpressure (relative to ambient (air) pressure). This allows for a particularly advantageous filling process.

[0055] In a further process step S114, after filling, the existing opening, or, if multiple openings are present, all existing openings in the sealing tape, can be closed. This can be achieved by any means that result in the existing opening(s) being closed, such as, in particular, applying another layer of sealing tape, preferably another layer of the sealing tape already applied in a previous step. Alternatively, the openings can also be closed by targeted prepolymerization or gelation of the filled casting resin, optionally induced by thermal energy, for example, by a focused laser pulse, or by a photochemical reaction through targeted irradiation with electromagnetic radiation of a suitable wavelength that induces prepolymerization, such as a UV laser pulse.In this way, an initial curing or gelation occurs such that the casting resin cannot escape through any of the openings of the casting package when it is transferred to a curing device. This is particularly important to avoid, as such casting resins often consist of harmful isocyanates and should never come into direct contact with production personnel. Additionally, such escaping casting resin can lead to irreversible contamination or damage of the base body, necessitating its disposal. Accordingly, in one embodiment, the casting package is removed from the holding device in a further process step S116 and preferably transferred to a curing device for further or complete curing.

[0056] In a further process step S118, the casting package can be cured, in particular completely. This curing process is understood to mean, in particular, that a curing process is initiated which results in the filled casting resin being converted into a solid state. Depending on the type and properties of the casting resin or the components forming the casting resin, such a curing process can optionally take place thermally or photochemically, or as a combination of both. Accordingly, in one embodiment, the curing of the casting package comprises thermal and / or photochemical and / or complete curing of the casting package. For thermal curing, the casting package is cured in an oven, which is the preferred thermal curing device. The casting package remains in this oven at a temperature and for a duration suitable for curing the casting resin used.For photochemical curing, the casting package is cured in a device comprising at least one receptacle suitable for holding the casting package and a radiation source suitable for emitting electromagnetic radiation of a wavelength suitable for curing the casting resin. In such a photochemical curing device, the casting package is irradiated with radiation of a certain wavelength and energy or energy density emitted from the radiation source for a predetermined duration in order to achieve curing of the casting resin.

[0057] In a further process step, the cast package is removed from the curing device after curing has occurred. The sealing tape is removed in a further process step S120. Preferably, this refers to the peeling off of the sealing tape, which can be accomplished using a suitable device.

[0058] In a further process step S122, the casting package is demolded, which means removing the mold shell. After removal of the mold shell, a lens is obtained, formed from a base body provided with a sprue, overlay, layer, or coating. The lens produced in this way can also be described as a multilayer lens or, in particular, as a two-layer lens.

[0059] As already emphasized, one or more of the aforementioned (further) process steps can also be omitted, for example the formation of at least one opening in the sealing tape, the closing of the opening and / or the hardening of the casting package.

[0060] Preferably, the flow behavior of the casting resin is improved by a suitable widening of the gate gap at least at the inlet opening. This can preferably be achieved by means of a mold shell that has a slightly different edge geometry, preferably implemented as a facet, at least in a region around the inlet opening. Due to this faceting of the mold shell, the distance between the mold shell and the base body is somewhat increased in the region of the inlet opening, resulting in a larger gap or the formation of a small chamber behind the inlet opening. This ensures a turbulence-free flow of the casting resin during filling, leading to reduced streaking and gas inclusions.In another embodiment, the widening of the gate gap can also be achieved by providing a correspondingly adapted geometry of the base body in the area of ​​the inlet opening, instead of faceting the mold shell. This is preferably achieved by faceting the base body, at least in the area of ​​the inlet opening. Alternatively or additionally, a widening of the gate gap can be realized by having both the mold shell and the base body have a widening; preferably, both the mold shell and the base body have such faceting. The faceting discussed in the various embodiments is present at least at the location of the inlet opening, but can also be implemented circumferentially and thus extend to the entire mold shell or the entire base body.Advantageously, such an expansion prevents turbulence and convection of the casting resin, thus avoiding the occurrence of casting streaks, inhomogeneities, and the resulting locally altered optical properties of the gate. In addition to improved resin flow, the widened gate gap also facilitates the installation of large-diameter inlet openings. Combined with the sealing filling device, this allows for high flow rates, particularly with highly viscous casting resins.

[0061] In one embodiment, the formed cavity has a gap widening or local increase in the gap width in an area around one or more of the openings in the sealing strip, wherein the gap width at a point in the cavity can be, in particular, the shortest distance between the mutually facing surfaces of the base body and the mold shell at that point in the cavity. In a further development, the base body, or preferably the mold shell and the base body (each), or especially preferably the mold shell alone, has a continuous, preferably linear, reduction of the cavity-bounding surface, at least in one section of the gap widening.

[0062] By shaping the mold shell to create the gap widening, the gap widening can be achieved particularly advantageously, and especially more easily. Advantageously, this avoids the need to shape the base body in a way that affects its optical properties, usable area, and / or further processing, and / or is more complex to manufacture than on the mold shell. A continuous, preferably linear, reduction of the cavity-bounding surface allows for particularly advantageous filling or resin flow, and / or enables the gap widening to be produced particularly easily and / or reliably.

[0063] In one embodiment, the gap widening extends over the entire circumference of the cavity. This allows for a particularly advantageous filling or flow of casting resin.

[0064] In one embodiment, at least one edge of the base body that limits the gap widening is removed from the resulting lens; in a further development, material is removed or separated. This ensures that the shape of the base body, intended for advantageously filling or (co-)forming the gap widening, does not impair the finished lens.

[0065] In one embodiment, one or more parameters of the process, and in a further development, at least one parameter of the filling of the cavity through the at least one opening with the casting resin, preferably a pressure during filling or the like, are set depending on the viscosity of the casting resin. In a further development, these parameters are adjusted during the execution of the (corresponding) process (step), preferably continuously regulated. In particular, an increase in viscosity over the service life can be at least partially compensated for by, for example, increasing the pressure during filling accordingly.

[0066] One aspect relates to a lens produced according to the inventive method or to spectacles or contact lenses provided with at least one such lens. It is understood that the application of such a lens is not limited to spectacle optics or contact lenses, but can also be used in other optical lenses in the fields of photography, projection, microscopy, illumination, for example in mobile phones, headlights, optical measuring instruments, etc.

[0067] One aspect concerns a device for carrying out a method according to the invention, which accordingly comprises one or more of the following devices: an opening device for forming the at least one opening in the sealing strip, a holding device for arranging and removing the casting package, a casting resin reservoir, a supply line and a sealing molded part for filling the cavity through the at least one opening with the casting resin, in a further development a pressing device for pressing the molded part and casting package against each other, a device for closing the at least one opening, and a curing device for curing the casting package.

[0068] One aspect concerns a casting package, in particular a casting package obtained by or used in a method according to the invention, which at least comprises: a base body, a mold shell, and a sealing strip, wherein the empty cavity, or the cavity filled with the casting resin, in particular the hardened one, is formed between the base or glass body and the mold shell.

[0069] In one embodiment, one or more, in particular all, steps of the process are carried out fully or partially automatically, in particular with the aid of the device.

[0070] Further advantages and features will become apparent from the dependent claims and the exemplary embodiments or the preferred embodiments described below in the figures. These show: Fig. 1: a schematic drawing of an embodiment of a casting package 1 in a frontal view, wherein the mold shell 11 and the base body 10 are arranged one behind the other in the direction of view, with a filling device 2 arranged therein; Fig. 2: a sectional drawing of the Fig. 1 along axis A, Fig. 3: an enlarged view of area Z from Fig. 2with three different embodiments for realizing an enlargement 5 (5a, 5b, 5c) of the gate gap, Fig. 4: an embodiment of a device for forming an opening in a sealing band of a casting package, Fig. 5: a method according to an embodiment of the present invention, and Fig. 6 - Fig. 8: various diagrams for viscosity and photochromism.

[0071] In the different figures, identical reference symbols represent the same elements.

[0072] Fig. 1 Figure 1 shows a schematic drawing of a casting assembly 1 in a frontal view. The mold shell or front mold 11 forming the casting assembly and the base body, in this exemplary embodiment a plastic base glass 10, are arranged one behind the other and are therefore not shown. An axis A has been drawn along the vertical axis of the casting assembly 1.

[0073] According to a preferred embodiment, the casting package 1 has a widening 5 of the gate gap in the area of ​​the inlet opening 16 and an outlet opening 17. In variations not shown, the outlet opening 17 can be omitted or more than one outlet opening can be provided, more than one inlet opening 16 can be provided, the inlet and / or outlet opening(s) can be positioned differently, and / or the widening 5 can be shaped differently, extending over the entire circumference or 360° in a particularly preferred variation.

[0074] Additionally shows Fig. 1A filling device 2, which is arranged at the inlet opening 16. In one embodiment, the filling device 2 has an element 23 for mechanical guidance, with which the filling device 2 can be precisely positioned at the inlet opening 16 by means of a robot arm as a preferred mechanical guide, in particular by connecting the robot arm to the mechanical guide 23 of the filling device 2.

[0075] Fig. 2 shows a cross-sectional drawing of the Fig. 1along axis AA. The casting package 1 comprises a base body 10 and a mold shell 11, wherein the base body 10 and mold shell 11 are positioned relative to each other such that a cavity 12 is formed between the base body 10 and the mold shell 11, which can be filled with a casting resin. The base body 10 and mold shell 11, as well as the cavity 12 located between them, are sealed or closed, preferably circumferentially, to be gas- and liquid-tight by means of a sealing strip 13. In the embodiment shown here, a filling device 2 is arranged below the casting package, comprising a resting and sealing molded part 20, which is preferably made of an elastic and conformable material to enable a precise fit of the filling device 2 to the casting package 1.Preferably, the material of the sealing molded part 20 is selected to exhibit high chemical resistance to the casting resins used. The filling device 2 also includes a supply line 21 through which the casting resin can be fed from a casting resin reservoir 24 into the cavity 12 of the casting package 1 during the filling process. In a preferred embodiment, the filling device 2, or in one embodiment the casting resin reservoir 24, includes a pressure device 22. This pressure device 22 allows the cavity 12 to be evacuated before filling, thereby creating a pressure equalization opening 17, which is understood to be an outlet opening 17 for the escape of air displaced during filling from the cavity. Furthermore, the pressure device 22 is also suitable for allowing the cavity 12 to be filled with a casting resin under a predetermined pressure.Advantageously, this allows the cavity 12 to be filled with a casting resin under increased pressure, resulting in a shorter filling time, especially when using high viscosity casting resins.

[0076] Fig. 3 shows an enlarged view of area Z for each of three different embodiments. Fig. 2In these embodiments, the area behind the inlet opening 16 has a widening 5 (5a, 5b, 5c), in particular a widening of the gate gap, which is implemented in different ways and serves to improve the flow behavior of the casting resin during filling with a filling device 2. Advantageously, the widening 5 (5a, 5b, 5c) of the gate gap leads to a reduced tendency for turbulence when filling the cavity 12 of the casting pack 1 with a casting resin, thereby preventing the formation of streaks and gas inclusions. Fig. 3a An embodiment is schematically depicted in which an enlargement 5a of the sprue gap is achieved by the mold shell having a faceting, at least in the area of ​​the inlet opening 16. Fig. 3bAnother embodiment is shown schematically, in which the widening 5b of the gate gap is achieved by faceting the base body, at least in the area of ​​the inlet opening 16. Fig. 3c Figure 1 shows a combined embodiment in which an enlargement 5c of the gate gap is achieved by faceting both the mold shell and the base body, at least in the area of ​​the inlet opening 16. As already explained, the enlargement 5 can be shaped differently in a modification not shown, and in a particularly preferred modification, extend over the entire circumference or 360°. In addition to improved resin flow, the enlargement of the gate gap also facilitates the incorporation of large-diameter inlet openings. In combination with the sealing filling device 2, high flow rates can thus be achieved, especially with higher-viscosity resins.

[0077] Fig. 4Figure 1 shows an embodiment of an opening device 3 for forming openings (16, 17) in a sealing strip 13 of a casting package 1. The opening device comprises an element 30 suitable for forming an opening (16, 17). Preferably, this element can be understood as a mechanical component with a pointed or sharp-edged border or shape, which is suitable for forming an opening (16, 17) in a sealing strip 13 of a casting package 1, preferably by cutting, punching, or perforating. In a preferred embodiment, the element 30 is a sharp knife blade with which an opening (16, 17) can be cut into a sealing strip 13 of a casting mold 1. Alternatively, the element 30 for forming an opening (16, 17) can also be an element with a heated or heated surface, which, by being directly arranged or touching a sealing strip 13 of a casting package 1, leads to thermal heating or heating.thermal decomposition of the sealing strip 13 at the point of contact leads to the formation of an opening (16, 17). Alternatively, the element 30 can also be a radiation source, in particular a source of pulsed laser radiation, with which, by applying one or more laser pulses, thermal heating or thermal decomposition of a sealing strip 13 at a point of contact leads to the formation of an opening (16, 17). Advantageously, when a laser source is used as the preferred element 30 for forming an opening, the opening device 3 does not need to be brought into direct contact with a sealing strip 13 of a casting package 1, but can be positioned at a distance from it.The opening device 3 can additionally have an element 31 for mechanical guidance, with which the opening device 3 can be precisely positioned at the inlet opening 16 by means of a robot arm as a preferred mechanical guide means, in particular by connecting the robot arm to the mechanical guide 31 of the opening device 3.

[0078] The robot-guided mechanical guide 23 allows the molded part 20 to be advantageously pressed against the casting pack with a defined, adjustable, or set contact pressure. Additionally or alternatively, a spring mechanism can be provided that presses the molded part against the casting pack and / or the casting pack against the molded part; accordingly, the Fig. 1The indicated element 23 may also represent or feature such a (partial) spring. The mechanical guide 23 may also include a fixation of the molded part 20 relative to the casting package arranged in the holding device, in particular, wherein the contact pressure can preferably be imposed by compression of the correspondingly elastic molded part 20 and / or a spring.

[0079] The embodiments and examples described above disclose a filling process according to the invention for casting a thin photochromic layer onto a plastic base glass 10, which advantageously allows the casting package to be filled without leaks and uncontrolled escape of casting resins.

[0080] For this purpose, a filling device or system 2 is provided, resting on the edge of the casting package 1, which consists of a front mold 11, a plastic base 10, and a circumferential sealing strip or tape 13. This filling device or system comprises an elastic molded part 20 resting on the sealing strip 13, which has high chemical resistance to the casting resin used, a resin feed or line 21, a pressure device 22, and a mechanical guide 23 for adjusting or pressing the molded part.

[0081] For creating a filling opening in the sealing tape, an apparatus or opening device 3 is provided, comprising a tool 30 which cuts an opening of defined size into the sealing tape material without damaging the mold shell and the base glass, or, in another example, creates the filling opening through thermal decomposition of the sealing tape material. Furthermore, the apparatus includes a mechanical device 31 that positions the filling opening so that it is subsequently enclosed by the sealing mold part 20 of the filling system. The resulting large-diameter opening enables filling with an optimized cross-section.

[0082] To improve the flow behavior of the casting resin and prevent casting streaks and gas inclusions, in addition to using the filling system 2, the mold shell and / or the base body of the casting package are adapted to the process requirements, and the adapted casting package is positioned in relation to the filling opening and the elastic molded part. With the molded part pressed into place, there is a widening 5 of the gate behind the filling opening, the shape of which is designed to ensure a low-turbulence flow of the casting resin. The recesses can be designed in various geometries that meet the aforementioned requirement: one possible, non-restrictive embodiment according to the invention is, for example, a chamfer on the edge of the casting package.The widening 5 of the gate gap can advantageously be provided by a recess in the front mold 5a, particularly advantageously by a linear recess of the cavity-defining surface of the front mold, a recess in the base glass 5b, preferably a linear recess of the cavity-defining surface of the base glass, or by opposing recesses in the mold and base glass 5c, advantageously linear recesses of the opposing cavity-defining surfaces. The widening of the gate gap is provided at least in the area of ​​the filling opening, but is not limited to this edge segment. As already mentioned, in a further embodiment not shown, the widening of the gate gap, in particular the recess 5a, 5b or 5c, is circumferential. The radial extent of the widening is preferably a few mm to avoid material loss.

[0083] Filling can be carried out in various casting package positions; preferably, it is performed in a tilted or upright position at the lower circular arc segment facing the filling opening. At least one opening in the sealing strip for pressure equalization during filling is provided at an opposite position.

[0084] In one embodiment, a filling process according to the invention is carried out as follows: A casting package with optimized component geometry (5a / 5b / 5c) and a small gap is provided. The casting package is positioned as described and perforated by the apparatus with the opening tool 30 at the sealing strip. Enclosing the filling opening, the elastic mold part 20 presses against the sealing strip. Under pressure, the photochromic acrylate or (thio)urethane casting resin is injected in a short time through the expanded circular ring or circular ring section of the casting package. After complete filling, the pressure equalization openings and then the filling opening are closed. The casting package can be removed and subjected to thermal or photochemical curing. After curing of the photochromic sprue, the upper mold shell is removed, and in a subsequent step, the product thus manufactured is machined to the desired diameter as required.This results in a raw, round spectacle lens according to the invention, of very good cosmetic quality with the desired photochromic properties, in a fast manufacturing process.

[0085] Fig. 5 shows a method according to an embodiment of the present invention comprising the steps: S100: Providing a basic body, S102: Provide a mold tray, S104: Arranging the base or glass body and the mold shell in such a way that a cavity is formed between the base or glass body and the mold shell. S106: Applying a sealing strip creates a seal between the base or glass body and the mold shell to maintain a casting package, S108: Forming at least one opening in the sealing tape, S110: Arranging the casting package in a holding device, S112: Filling the cavity through at least one opening with a casting resin, S114: Closing the opening, S116: Removing the casting package filled with casting resin from the holding device, S118: Curing of the casting package, S120: Removing the sealing tape, and S122: Removing the mold shell to obtain a lens.

[0086] The following are specific examples of photochromic lenses which have a sprue made of poly(thio)urethane casting resin with high-viscosity fused naphthopyran dyes, or in which the sprue is produced by filling the cavity of the casting package through at least one opening with a poly(thio)urethane casting resin with high-viscosity fused naphthopyran dyes, or by a (sprue) process according to the invention using a seal, a base body, a mold shell and a gap widening in the area of ​​the (filling) opening.

[0087] This process is particularly advantageous for all thermally or photochemically curing polymer casting resins. Specifically, it can be used for polyurethanes, polythiourethanes and their mixtures, for thermally and photochemically curable polyacrylates, polymethyl methacrylates and their mixtures, and for thermally curable polycarbonates. Polyurethanes and polythiourethanes, as well as their mixtures, are produced by polyaddition from the corresponding monomers. The step growth of the polyaddition reaction can lead to a rapid increase in viscosity after mixing the casting resin.

[0088] The following Table 1 and Diagram 1 ( Fig. 6Figure 1 shows an example of the viscosity profile of a casting resin mixture A (composition of example E0, see Table 2), which was stirred under laboratory conditions after preparation and subsequent evacuation (3 x 10⁻¹ < mbar). Viscosity measurements were taken from samples of the casting resin mixtures using viscometers. Rotavisc LO-VI (IKA) and Visconorm DD (Gel Instruments) were used.

[0089] Table 2 shows various examples of a sprue or a casting resin for filling the cavity of the casting package in an inventive (sprue) process or a casting package or a lens produced according to the invention:

[0090] In the examples, resin mixtures containing MR8 components (Mitsui Chemicals) were chosen as the MR8 substrate material, although comparative tests showed that other substrate materials also yielded advantageous results. The sample lenses produced in these and other test series were examined for their photochromic properties. Measurements at 23 °C were performed according to DIN EN ISO 8980-3:2022 on a special test setup equipped with MCS 551 Vis diode array spectrometers (Carl Zeiss Spectroscopy) and LSH 201 xenon arc lamps (LOT) with a 300 W Xe OF lamp (Ushio) for excitation. The maximum darkening τv1 after 15 min of excitation and the half-life of the brightening from τv1 to τv0 (unexcited state) are listed in Table 2.

[0091] In the casting resin mixture for example E1, an fused 2H-naphthopyrane was used as photochromic dye A according to the following formula 1. According to formula 1, the dye has an N-morpholinyl group as substituent R1 and is substituted via a succinic acid bridge with a linear polypropylene oxy chain. The large length of p > 40 units and the use of polypropylene oxy units allow its incorporation into the monomer mixture of the thiourethane casting resin and the preservation of good photochromic properties.

[0092] For the preparation of dye mixture A for viscosity tests E0, as well as for the preparation of examples E2 (mixture B), E3 (mixture B) and E4 (dye B), dyes from the group of indenonaphthopyrans according to formula 2 are used. These dyes are disclosed in particular in WO 2019 / 238495.

[0093] The dyes carry linear polypropylene oxy chains with p ≥ 10 according to formula 2. The residues R1, R2, and R3 each independently represent a substituent selected from hydrogen, bromine, chlorine, fluorine, a (C1-C6) alkyl group, a (C3-C7) cycloalkyl group, a (C1-C6) thioalkyl group, a (C1-C6) alkoxy group, a hydroxy group, a tert-butyl dimethylsilyloxy group, a tert-butyl diphenylsilyloxy group, a trifluoromethyl group, a phenyl group, a phenoxy group, a benzyl group, a benzyloxy group, a biphenyl group, a biphenyloxy group, a naphthyl group, a naphthoxy group, a Mono-(C1-C6)-alkylamino residue, a di-(C1-C6)-alkylamino residue, a phenylamino residue, a diphenylamino residue, a piperidinyl residue, a 3,5-dimethylpiperidinyl residue, an indolinyl residue, a morpholinyl residue, a 2,6-dimethylmorpholinyl residue, a thiomorpholinyl residue, an azacycloheptyl residue, a phenothiazinyl residue,a phenoxazinyl residue, a 1,2,3,4-tetrahydroquinolinyl residue, a 1,2,3,4-tetrahydroisoquinolinyl residue, a phenazinyl residue, a carbazolyl residue, a 1,2,3,4-tetrahydrocarbazolyl residue, or a 10,11-dihydro-dibenz[b,f]azepinyl residue; , or the two adjacent residues R1 and R2 represent the group -V-(CH2)rW-, where V and W are independently selected from the groups -O-, -S-, -N(C1-C6)-alkyl-, -NC6H5-, -CH2-, -C(CH3)2-, -C(C2H5)2- or -C(C6H5)2-; r represents an integer from 1 to 3; if this numerical value is 2 or 3, a benzene ring may also be fused to two adjacent CH2 groups; V or W may together with the respective adjacent CH2 group also represent a fused benzene ring; and wherein the residues R 4 , R 5 , R 6 , each independently represent a substituent selected from hydrogen, a (C 1 -C 6 )-alkyl residue, a (C 3 -C 7 )-cycloalkyl residue, a phenyl residue, a benzyl residue, a biphenyl residue or a naphthyl residue; m represents an integer from 1 to 3;or two adjacent residues R4 form an annelated benzene ring, which may be unsubstituted, mono- or disubstituted, wherein the substituents may be selected from hydrogen, a (C1-C6) alkyl group, a (C1-C6) alkoxy group, a phenyl group, a benzyl group, a biphenyl group or a naphthyl group; or residues R5 and R6, together with the carbon atom bonded to these residues, form a three- to eight-membered carbo- or heteromonocyclic ring to which one or two aromatic or heteroaromatic ring systems may be annelated, wherein the ring system(s) are / are independently selected from benzene, naphthalene, phenanthrene, pyridine, quinoline, furan, thiophene, pyrrole, benzofuran, benzothiophene, indole and carbazole.

[0094] Example E1 consists of lenses made from sprues on polythiourethane plastic glass substrates. These are prepared, preferably pre-produced, in process step S100 and are made from a casting resin mixture with MR8 components (Mitsui Chemicals). These widely used mixtures result in optical plastic material with a refractive index n 1.6. To simplify index matching, the sprue is also based on MR8 poly(thio)urethane casting resin. The isocyanate component according to Table 2 is added, and a photochromic dye according to Formula 1 with a linear polypropylene oxy substitute is added. Then, at room temperature, the remaining components for the formation of the poly(thio)urethane and the catalyst dibutyltin dichloride are added while stirring. The clear solution is evacuated for 1 h (3 x 10⁻¹ < mbar). After a settling time according to Table 2, the casting resin thus obtained is filled into the casting package in process step S112.The curing process takes place over a temperature range between room temperature and 125 °C. The result is clear lenses with good photochromic properties.

[0095] In diagram 2 (see Fig. 6 ; Diagram 1 shows an example of the viscosity profile of the casting resin mixture A) the transmission profile of a correspondingly produced sample body without optical effect is shown.

[0096] Examples E2 and E3 are produced using the same method as Example E1. These examples were produced in larger quantities using a production system (evacuable, temperature-controlled stirred tank for casting resin). Table 3 shows, using mixtures B1 and B2 as examples, how the parameters mentioned above lead to an increase in the viscosity of the photochromic casting resin mixture: in this example, the resin's service life after mixing, temperature, and the concentration of the catalyst dibutyltin dichloride. The mixture B2 used for Examples E2 and E3 contains 500 ppm catalyst, various polythiols, polyols, and the dye mixture B consisting of dyes of formula 2 (see Table 2). Examples E2 and E3 demonstrate the production of samples with short and long service lives in the circulating casting resin reservoir of a filling device according to the invention.While example E2 was easy to produce due to its low viscosity, the requirements for E3 are considerably higher after several hours of resin settling time (see Table 3, Diagram 3). Fig. 7 ).

[0097] Diagram 3 (see Fig. 7 ) shows the viscosity curve of the casting resin mixtures B1 and B2 with different catalyst concentrations at two temperatures and illustrates the advantages of the inventive process for series production with longer service life of the casting resin at high quantities and higher temperatures.

[0098] The casting resin for example E2 has a relatively low viscosity, while the resin for E3 has a long service life and a correspondingly higher viscosity. In both cases, clear, high-quality lenses with good photochromic properties are obtained. A key advantage for mass production is that the photochromic properties are independent of the service life of the casting resin (see diagram 4 in [reference]). Fig. 7 , measurement as described for example E1). Neither the resin dwell time nor the temperature in the resin reservoir showed a significant influence on the photochromic properties, as can also be seen from Table 2 (cf. transmission in the darkened state T s ; half-life of lightening; Diagram 4, Fig. 7 ). With a (casting) process according to the invention, reproducible production and reliable pairing of the photochromic products can advantageously be ensured.

[0099] Example E4 is produced using the same method as Example E1. The casting resin contains 500 ppm catalyst, various polythiols, polyols, the single dye B according to formula 2, and an epoxy as an adhesion-promoting additive (see Table 2). Clear lenses with photochromic properties are obtained. In Diagram 5 (cf. Fig. 8 Figure 1 shows the transmission profile of a specimen produced using the casting process without optical effects. The maximum darkening τv1 after 15 minutes of excitation and the half-life of the lightening from τv1 to τv0 (unexcited state) are listed in Table 2.

[0100] In the present disclosure, "has an X" does not generally imply an exhaustive list, but is a shorthand for "has at least one X" and also includes "has two or more X" as well as "has Y in addition to X". Although exemplary embodiments were explained in the preceding description, it should be noted that a multitude of variations are possible. Furthermore, it should be noted that the exemplary embodiments are merely examples and are not intended to limit the scope of protection, applications, or structure in any way.Rather, the preceding description provides the skilled person with a guide for implementing at least one exemplary embodiment, whereby various modifications, particularly with regard to the function and arrangement of the described components, can be made without leaving the scope of protection as defined by the claims and these equivalent combinations of features. Reference symbol list

[0101] 1 Casting package 2 Filling device 3 Opening device 5 Expansion 5a Expansion into mold shell 5b Expansion into base body 5c Expansion into mold shell and base body 10 Base body 11 Mold shell 12 Cavity 13 Sealing tape 16 Inlet opening 17 Outlet opening 20 Mounting part 21 Resin supply line 22 Pressure device 23 Mechanical guide 24 Resin reservoir 30 Element for forming an opening 31 Mechanical device

Claims

1. A method for manufacturing a lens, in particular a spectacle lens, comprising at least the following steps: - S100:Obtaining a base body (10),- S102:Obtaining a mold shell (11),- S104:Arranging the base body (10) and the mold shell (11) such that a cavity (12) is formed between the base body and the mold shell,- S106:Applying a sealing tape (13) to thereby seal the cavity (12) formed between the base body (10) and the mold shell (11) to obtain a casting package (1),- S112:Filling the cavity (12) through at least one opening (16, 17) with a casting resin,- S120:Removing the sealing tape (13), and- S122:Removing the mold shell (11) to obtain the lens, characterized in that - filling the cavity (12) comprises filling the cavity with the casting resin from a casting resin reservoir (24) through a supply line (21), a sealing part (20) that comprises at least one elastic layer adapted for resting on the casting package (1) at least during the filling, and comprises at least one opening (16, 17), and - the sealing part (20) and the casting package (1) are pressed against each other, and - a gap dimension of the cavity (12) is less than one thousand micrometers.

2. A method according to claim 1, characterized in that the cavity (12) is filled under excess pressure and / or at least partially against the direction of gravity.

3. A method according to claim 1 or 2, comprising at least one of the following steps: - S108:Forming at least one opening (16, 17) in the sealing tape (13),- S110:Arranging the casting package (1) in a holding device,- S114:Closing the opening (16, 17),- S116:Removing the casting package (1), filled with a casting resin, from the holding device,- S118:Curing the casting package (1).

4. A method according to one of the preceding claims, characterized in that the sealing part (20) and the casting package (1) are pressed against each other by means of a pressing device.

5. A method according to any of the preceding claims, characterized in that the formation of at least one opening (16, 17) in the sealing tape (13) takes place after the sealing tape (13) has been applied and / or by means of an opening device (3), in particular mechanically and / or thermally and / or by means of laser light.

6. A method according to any one of claims 2-5, characterized by adjusting the sealing mold part (20) and / or the opening device (3) relative to the casting package (1) arranged in the holding device by means of a mechanical guide (23).

7. A method according to any of the preceding claims, characterized in that at least two openings (16, 17) are formed in the sealing tape (13), wherein the cavity (12) is filled with the casting resin through a first (16) of these openings (16, 17), wherein the cavity (12) is also filled with the casting resin through at least a second (17) of these openings (16, 17) and / or, during filling, gas escapes from the cavity (12) through at least a second (17) of these openings (16, 17).

8. A method according to any of the preceding claims, characterized in that the casting resin forms a photochromic coating.

9. A method according to any of the preceding claims, characterized in that the formed cavity (12) has a gap widening (5, 5a, 5b, 5c) in a region around the at least one opening (16, 17).

10. A method according to claim 9, characterized in that the mold shell (11) and / or the base body (10) comprises, at least in a section of the gap widening (5, 5a, 5b, 5c) a continuous, in particular linear, tapering of the cavity-bounding surface and / or the gap widening (5, 5a, 5b, 5c) extends over the entire circumference of the cavity and / or, in the resulting lens, at least one base body edge delimiting the gap widening (5, 5a, 5b, 5c) is removed.

11. A method according to any of the preceding claims, characterized in that the sealing tape (13) comprises a carrier material and / or an adhesive.

12. A method according to any of the preceding claims, characterized in that the curing of the casting package (1) comprises thermal and / or photochemical curing of the casting package and / or that at least one process parameter is adjusted as a function of the viscosity of the casting resin and / or that the casting resin has a viscosity of up to 800 mPas during filling and / or in the uncured state and / or comprises one or more or a combination of two or more of the following: in particular thermally curable, polyurethane and polythiourethane casting resins, polyacrylate and polymethyl methacrylate casting resins, in particular thermally and / or photochemically curable polyacrylate and polymethyl methacrylate casting resins, polycarbonate and polydiethylene glycol bis(allyl carbonate) casting resins, in particular thermosetting polycarbonate and polydiethylene glycol bis(allyl carbonate) casting resins, multifunctional isocyanates, isothiocyanates and / or episulfides, multifunctional alcohols and / or thiols, multi- and / or monofunctional acrylates and / or methyl methacrylates, multi- and / or monofunctional allyl carbonates and / or diethylene glycol bis(allyl carbonates).

13. Apparatus for carrying out a process according to any of the preceding claims, comprising the following devices: - means for providing the base body (10), - means for providing the mold shell (11), - means for attaching the sealing tape (13) to seal the cavity (12) formed between the base body (10) and the mold shell (11) to obtain a casting package (1), - the holding device for positioning and removing the casting package (1), - the casting resin reservoir (24), the supply line (21) and the sealing part (20) for filling the cavity (12) through the at least one opening (16, 17) with the casting resin, wherein the sealing part (20) comprises at least one elastic layer adapted for resting against the casting package (1), and - the pressure-applying device for pressing the sealing part (20) and the casting package (1) against each other.

14. Apparatus according to claim 13, wherein the apparatus further comprises: - the opening device (3) for forming the at least one opening (16, 17) in the sealing tape (13), and / or - a device for closing the at least one opening (16, 17), and / or - a curing device for curing the casting package (1).